Sprayer for at least one fluid

ABSTRACT

One exemplary embodiment can be a sprayer for distributing at least one fluid in a vessel. The sprayer can include a first member having a first surface and a second surface forming at least one aperture there-through. Generally, the at least one aperture is skewed with respect to a substantially vertical axis passing through a center of the first member for distributing the at least one fluid in the vessel.

FIELD OF THE INVENTION

The invention generally relates to a sprayer for at least one fluid.

DESCRIPTION OF THE RELATED ART

Various vessels can be used in chemical processing, petroleum refining,and other industries for distributing fluids, particularly a mixed-phasefluid of liquid and gas over beds or trays. One particular vessel can bea reactor, such as a trickle flow reactor, that can be used in processessuch as catalytic dewaxing, hydrotreating, hydrodesulfurization,hydrofinishing, and hydrocracking. Generally, a feed, such as a fluidincluding one or more liquids and gases, can pass over a particulatecatalyst contained in a packed bed in a downflow reactor. Chemicalreactions can take place that may produce additional components in a gasphase, such as hydrogen sulfide and ammonia, in some hydrotreatingprocesses. Such gases may separate from the liquid and rise to the topof the reactor to exit at an upper outlet. The liquid typically flowsdownward through the packed bed and exits a bottom outlet.

To facilitate reactions, a solid catalyst is often arrayed in aplurality of beds with a distributor plate or tray above each bed forthe purpose of uniformly, effectively, and efficiently distributing thefluid at the top of the bed.

Generally, trays can be provided with distributors to provide an equallydivided flow across the underlying bed. However, these distributors cansuffer from shortcomings when, for example, ideal conditions are notpresented and an unequal distribution of liquid occurs. As an example,non-ideal distribution conditions can exist during the start-up of aunit, e.g., after maintenance is conducted. These non-ideal conditionscan lead to an inefficient wetting of the catalyst bed below thedistributor. This uneven wetting can create hotspots in the catalyst bedleading to one or more pockets of shortened catalyst life. In addition,an uneven flow of liquid can create channeling through the bed. As aconsequence, it is desirable to provide a distributor that providesbetter and consistent wetting of the underlying catalyst bed to avoidthese shortcomings and extend the catalyst life.

SUMMARY OF THE INVENTION

One exemplary embodiment can be a sprayer for distributing at least onefluid in a vessel. The sprayer can include a first member having a firstsurface and a second surface forming at least one aperturethere-through. Generally, the at least one aperture is skewed withrespect to a substantially vertical axis passing through a center of thefirst member for distributing the at least one fluid in the vessel.

Another exemplary embodiment can be a vessel for distributing at leastone fluid. The vessel may include a distributor and a packed bedincluding a plurality of particles positioned below the distributor. Inaddition, generally the distributor includes a tray forming at least onevoid, a conduit coupled to the tray about the void and passingthere-through; and a sprayer coupled proximate to a bottom end of theconduit. Furthermore, the sprayer may include a first member forming aplurality of diverging apertures there-through, and having a firstsurface and a second surface.

A further exemplary embodiment may be a process for distributing atleast one hydrocarbon fluid. The process can include passing the atleast one hydrocarbon fluid through a conduit to a sprayer. What ismore, the sprayer can include a first member forming a plurality ofdiverging apertures, and having a first surface and a second surface.

The embodiments disclosed herein can provide a sprayer that can preventhot spots and channeling in a packed bed by providing a consistent andsufficient liquid distribution. The sprayer can have several designfeatures that can be adapted to provide a suitable spray for aparticular vessel. As such, multiple sprayers may provide overlap andredundancy should a sprayer become inoperable by, e.g., plugging. Inaddition, the increased effectiveness of the sprayer can reduce thenumber of sprayers required for a particular vessel. Thus, the improvedsprayer may extend catalyst life by preventing hot spots or channelingthat can reduce the life of the catalyst and/or make the reactor lesseffective.

DEFINITIONS

As used herein, the term “fluid” can mean one or more gases and/or oneor more liquids.

As used herein, the term “gas” can mean a single gas or a solution of aplurality of gases. In addition, the term “gas” may include a solutionor a suspension, e.g., a vapor or an aerosol, of one or more liquidparticles and/or one or more solid particles, of the same or differentsubstances, in one or more gases.

As used herein, the term “liquid” can mean a single liquid, or asolution or a suspension of one or more liquids with one or more gasesand/or solid particles.

As used herein, the terms “absorbent” and “absorber” include,respectively, an adsorbent and an adsorber, and relates, but is notlimited to, absorption, and/or adsorption.

As used herein, the term “rich” can mean an amount generally of at leastabout 50%, and preferably about 70%, by mole, of a compound or class ofcompounds in a stream.

As used herein, the term “perimeter” generally means a boundary of anobject or region, and can be of any suitable shape, such as a circle,oval, square, diamond, rectangle, or irregular.

As used herein, the term “coupled” can mean two items, directly orindirectly, joined, fastened, associated, connected, or formedintegrally together either by chemical or mechanical means, by processesincluding stamping, molding, or welding. What is more, two items can becoupled by the use of a third component such as a mechanical fastener,e.g. a screw, a nail, a staple, or a rivet; an adhesive; or a solder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational, side view of an exemplary vessel.

FIG. 2 is a top, plan view of an exemplary sprayer.

FIG. 3 is a bottom, plan view of the exemplary sprayer.

FIG. 4 is a side, elevational view of the exemplary sprayer.

FIG. 5 is an elevational, side view of the exemplary sprayer.

FIG. 6 is a schematic, top, and plan view of an exemplary collectiondevice.

FIG. 7 is a graphical depiction comparing distribution patterns.

DETAILED DESCRIPTION

Referring to FIG. 1, a vessel 100 is depicted having an inlet 110, afirst outlet 120, and a second outlet 130. The vessel 100 can receive afeed. The feed can be a fluid, including a liquid or a mixed-phasefluid, such as one or more liquids and gases, through the inlet 110.Generally, the vessel can distribute the feed in the vessel containing afixed bed of particles, such as a catalyst. Although a reactor isdisclosed herein, it should be understood that other types of vesselssuch as an absorber or a mass transfer vessel can also use theembodiments disclosed herein, and other materials can be containedinstead of or in addition to the catalyst, such as an absorbent.

The vessel 100 can include a distributor 200 and a packed bed 400 ofparticles, such as a catalyst. The distributor 200 can include a tray220 forming at least one opening 224 and at least one void 228. Althoughonly one tray 220 and one packed bed 400 are depicted in this exemplaryembodiment, it should be understood that the vessel 100 can contain anynumber of trays 220 and packed beds 400. In addition, although a feed isdiscussed as being distributed, any stream or fluid may be distributed,including intermediate streams internal to the vessel 100 or recycledstreams. Generally, the distributor 200 further includes at least oneriser 240 and at least one conduit or downcomer 260 that allows thepassage of a fluid, such as a liquid or a mixed-phase fluidthere-through. In this exemplary embodiment, two risers 240 and threedowncomers 260 are depicted, although any number of risers 240 and/ordowncomers 260 can be utilized. The at least one riser 240 can include afirst riser 242 and a second riser 244 and the at least one downcomer260 can include a first downcomer 262, a second downcomer 272, and athird downcomer 282. Generally, one or more gases rise through therisers 240, and one or more fluids, including a fluid rich in one ormore liquids, flow downward through the downcomers 260. The risers 240and the downcomers 260 may be spaced apart in order to minimizedisturbance of a liquid film flow or a spray by interaction with arising gas flow.

The vessel 100 in exemplary embodiments can be adapted for co-current orcounter-current flow. In one exemplary embodiment, the gas and liquidcan be in a co-current downward flow, such as a hydrotreating vessel. Insuch an instance, the risers 240 can be integrated with the downcomers260 as a single unit, and the gas and liquid can descend to the packedbed 400. Alternatively, the risers 240 can be omitted and the gas andliquid can flow downward through the downcomers 260.

As depicted herein, generally the risers 240 surround a respectiveopening 224 and the downcomers 260 surround a respective void 228 in thetray 220. The downcomers 260 can include a respective sprayer 300.Particularly, each downcomer 262, 272, and 282 can include a respectivefirst sprayer 310, a second sprayer 312, and a third sprayer 314.Generally, the distribution and density of the downcomers 260 are suchthat the liquid films or droplet sprays from neighboring downcomers 260overlap. Therefore, the downcomers 260 are preferably evenly distributedover the tray 220. As an example, the distributor 200 can have at least25 downcomers 260 per square meter of tray 220.

The downcomers 260 and corresponding sprayers 300 can be the same ordifferent, but in this exemplary embodiment each downcomer 260 and eachsprayer 300 can be substantially similar to, respectively, otherdowncomers 260 and sprayers 300. As such, only downcomer 262 and itsrespective sprayer 310 are described in greater detail herein.

The downcomer 262 can form an opening 264 and have a bottom end 266. Thedowncomer 262 can have a generally tubular or cylindrical shape, but itshould be understood that the downcomer 262 can be any suitable shape,such as prism-shaped. Generally, the feed flows from the inlet 110 tothe tray 220, which is substantially horizontal. The liquid collected onthe tray 220 can rise and enter the opening 264 and pass downwardthrough the sprayer 310 to the packed bed 400 below the tray 220.

Referring to FIGS. 1-5, the first sprayer 310 can include a center 304,a substantially vertical axis 308, a first member 320, a second member360, and at least one leg or plurality of legs 380. Typically, the firstmember 320 is spaced apart from the second member 360. The first member320 can have a shape of a frustum 322 and have a first surface 330 and asecond surface 340. Generally, the first surface 330 and the secondsurface 340 are substantially parallel, and have respectively, adiameter 332 and a diameter 342. The second surface 340 can form aperimeter 344. Generally, the perimeter 344 can be substantiallycircular 346, but can be any suitable shape such as rectangular orsquare. The substantially circular perimeter 346 can form a serratededge 348 to aid the distribution of, e.g., a feed. However, it should beunderstood that the serrated edge 348 can take other shapes to aid thedistribution of liquid. Typically, the first member 320 forms at leastone aperture 350 there-through, preferably a plurality of divergingapertures 350, with respect to the substantially vertical axis 308. Inthis preferred embodiment, the first member 320 forms twelve apertures350, although the first member 320 may form any number of apertures 350.Usually, each aperture 350 can be skewed with respect to thesubstantially vertical access 308, and may be substantially circular andhave a diameter 352. The skewed apertures 350 can be, independently, thesame or different. The skewed apertures 350 may aid in the dispersion ofa liquid. In addition, the diameter of the first member 320 can be afunction of the diameter and the pitch of downcomers of the tray 220.The ratio of the diameter 342 of the second surface 340 of the firstmember 320 to the diameter 352 of one of the at least one aperture 350can be about 10:1-about 45:1, preferably about 20:1-about 25:1. In thisexemplary embodiment, the diameter 332 of the first surface 330 to thediameter 342 of the second surface 340 can be about 1:1.1-about 1:4,preferably about 1:1.5-about 1:3, and optimally about 1:2.

The second member 360 can be a substantially cylindrical shape 364,although the second member 360 can form any suitable shape, and form atleast one slot 368. In this exemplary embodiment, the second member 360can form three slots 368, although any number of one or more slots 368can be formed. Each slot 368 can be, independently, the same ordifferent, but are preferably the same. Typically, the second member 360is adapted to couple the bottom end 266 of the downcomer 262.Particularly, the downcomer 262 can have one or more screws or othertype of mechanical fastener projecting from its bottom end 266 that isreceived within a respective slot 368 for coupling of the sprayer 310thereto. Alternatively, the second member 360 can couple the downcomer262 using any suitable means, such as welding.

In addition, at least one leg or plurality of legs 380 can couple thefirst member 320 and the second member 360. Preferably, the plurality oflegs 380 can include a first leg 382, a second leg 384, a third leg 386,and a fourth leg 388, although any number of one or more legs 380 can beutilized. Each leg 380 can have a respective length 390, and may be thesame or different. Typically, the first member 320, the second member360, and the plurality of legs 380 are formed integrally together by anysuitable means, such as welding. The length 390 of a single leg 380 to adiameter 342 of the second surface 340 can have a leg length:diameterratio of about 1:2-about 1:15, preferably about 1:5-about 1:10, andoptimally about 1:7.

Generally, the spray device 310 is designed to couple with any suitabledowncomer 262. Particularly, the sprayer 310 can be coupled onto severalkinds of downcomers. Moreover, the sprayer 310 may be designed tominimize the pressure drop through the downcomer, while discharging adispersed spray of liquid droplets. The unique geometric features of thesprayer 310, such as the frustum-shaped first member 320, the serratededge 348, and the diverging plurality of apertures 350, can facilitatethe dispersion of liquid without substantially increasing the pressure.In addition, generally the frustum 322 shape of the first member 320further aids the dispersion of liquid. This combination of features mayensure the spread and dispersion of a fluid to the packed bed 400 below.The dimensions of the first member 320, the number of apertures 350 andtheir angular orientation, the number of serrations along the serratededge 348, and the diameter and angle of the frustum 322 can all bedesigned to optimize spray patterns to overlap the spray of neighboringsprayers for obtaining a sufficient liquid distribution, even in theevent of a sprayer becoming dysfunctional due to, e.g., plugging. Thus,these dimensions can be designed to provide a broad distribution of anumbrella-shaped film or spray.

In operation, the feed collected on the tray 220 may rise and passthrough the opening 264 of the downcomer 262. Afterwards, the fluid canenter the first sprayer 310 proximate to the second member 360. Thefirst member 320 is spaced apart from the second member 360 so the fluidcan fall freely to the first surface 330 of the first member 320. As aresult, the fluid can gain momentum, and upon impingement, the fluid mayform a broad film or droplet spray. The overlapping of films and/orsprays from neighboring sprayers can provide a high uniformity ofdistribution.

EXAMPLES

The following examples are intended to further illustrate the disclosedembodiments. These illustrations of the embodiments are not meant tolimit the claims to the particular details of these examples. Theseexamples can be based on engineering calculations and actual operatingexperience with similar processes.

The following experiment can demonstrate the effectiveness of thesprayer disclosed herein by quantitatively measuring the spatial spreadof a fluid, such as a liquid, dispersed from the sprayer. The dischargedliquid can be collected over a specified area underneath the sprayer.Discharge fractions may be collected in subdivided areas and used toassess the effectiveness of the sprayer.

Referring to FIG. 6, a collection apparatus 500 can be positionedunderneath a tubular downcomer 562 depicted in phantom. The collectionapparatus 500 can be one or more tubes 510 including three concentrictubes 520, 530, and 540 of generally incrementally increasing diameterplaced directly underneath the downcomer 562. The tube 520 has a 13centimeter (cm) diameter and fashioned from a schedule 40 pipe, the tube530 has a 20 cm diameter and fashioned from a schedule 80 pipe, and thetube 540 has a 25 cm diameter and fashioned from a schedule 40 pipe.Each tube 510 can be 46 cm long to provide a collection volume. Thesetubes 510 create four zones, namely a Zone A inside the tube 520, a ZoneB between the tubes 520 and 530, a Zone C between the tubes 530 and 540,and a Zone D outside the tube 540. The collection area for each of theZones A, B, and C is about 130 square cm. The lower end of each tube 510can be closed by a plate forming three discharging orificescorresponding to each of the Zones A, B, or C. The orifices can becalibrated to discharge a certain amount of liquid, e.g. water,depending on the head of the collected water inside each Zone A, B, orC. The flow rates can be calculated by measuring the height of the waterin each Zone A, B, or C by means of a differential pressure gaugeconnected to pressure ports on the lower end of each respective tube510.

The distributor setting on a tray has a triangular pitch of about 11 cm.The spray from the downcomer may extend beyond the outermost tube 540.The amount of water in Zone D is calculated by subtracting the amountsof water in Zones A-C from the amount of water passed through thedowncomer 562.

It is generally desired that a downcomer provides an even distributionof a fluid so that the amounts collected in Zones A, B, C, and D areabout equal. Thus, the even distribution of a fluid, such as water, inall four zones would generally be a preferred characteristic of adowncomer.

Referring to FIG. 7, distribution patterns are compared of a splashplate coupled to the downcomer 562, a sprayer 310 as depicted in FIGS.1-5 coupled to the downcomer 562, and the downcomer 562 with no terminalsprayer. The splash plate can be connected to a cuff and spaced about1.5 cm from the cuff's lower end. The splash plate can be circular inshape having a smooth edge and with a diameter of about 11 cm. Thesplash plate can form 37 evenly-spaced non-diverging holes, i.e.parallel, to a perpendicular axis, and each hole can have a diameter ofabout 0.5 cm. The second surface 340 of the sprayer 310 can have adiameter of about 11 cm. Approximately equal amounts of water areprovided in the downcomer 562 for testing with the splash plate, thesprayer 310, and no sprayer. As depicted in FIG. 7, the collected flowrate in liters per minute (lpm) is compared at each zone for thedowncomer 562 having the splash plate, the sprayer 310, and no sprayer.The splash plate distributes liquid in a pattern that is reminiscent ofan umbrella, namely a central stream in zone A and droplets dispersedinto zone D. There is little or no distribution in zones B and C. Thesprayer 310 provides more evenly spaced distribution over the spacecontinuum, with relatively significant amounts in Zones A, B, and D anda small amount in Zone C. The downcomer 562 absent a sprayer distributesalmost all the water in Zone A.

Without further elaboration, it is believed that one skilled in the artcan, using the preceding description, utilize the present invention toits fullest extent. The preceding preferred specific embodiments are,therefore, to be construed as merely illustrative, and not limitative ofthe remainder of the disclosure in any way whatsoever.

From the foregoing description, one skilled in the art can easilyascertain the essential characteristics of this invention and, withoutdeparting from the spirit and scope thereof, can make various changesand modifications of the invention to adapt it to various usages andconditions.

1. A sprayer for distributing at least one fluid in a vessel,comprising: 1) a first member having a first surface and a secondsurface forming at least one aperture there-through wherein the at leastone aperture is skewed with respect to a substantially vertical axispassing through a center of the first member for distributing the atleast one fluid in the vessel.
 2. The sprayer according to claim 1,wherein the first member generally forms a frustum.
 3. The sprayeraccording to claim 1, wherein the at least one aperture comprises aplurality of apertures.
 4. The sprayer according to claim 3, wherein theplurality of apertures diverge from the axis.
 5. The sprayer accordingto claim 1, wherein the first surface and the second surface aresubstantially parallel.
 6. The sprayer according to claim 5, wherein thesecond surface forms a serrated edge about a perimeter.
 7. The sprayeraccording to claim 6, wherein the perimeter is substantially circular.8. The sprayer according to claim 1, further comprising: a second membercoupled to the first member wherein the first and second members arespaced-apart.
 9. The sprayer according to claim 8, wherein the secondmember is substantially cylindrically shaped.
 10. The sprayer accordingto claim 9, wherein the second member forms at least one slot.
 11. Thesprayer according to claim 10, further comprising at least one legcoupling the first member to the second member.
 12. The sprayeraccording to claim 11, further comprising a plurality of legs.
 13. Thesprayer according to claim 12, wherein the at least one aperturecomprises a plurality of apertures wherein the plurality of aperturesdiverges from the axis.
 14. The sprayer according to claim 13, whereinthe second surface of the first member forms a serrated edge about aperimeter.
 15. A distributor for at least one fluid, comprising: a trayfor receiving a fluid wherein the tray forms a void; a conduit coupledto the tray about the void and passing there-through; and a sprayeraccording to claim 1 coupled proximate to a bottom end of the conduit.16. A vessel for distributing at least one fluid, comprising: I) adistributor wherein the distributor comprises: A) a tray forming atleast one void; B) a conduit coupled to the tray about the void andpassing there-through; and C) a sprayer coupled proximate to a bottomend of the conduit; wherein the sprayer comprises: 1) a first memberforming a plurality of diverging apertures there-through, and comprisinga first surface and a second surface; II) a packed bed comprising aplurality of particles positioned below the distributor.
 17. The vesselaccording to claim 16, wherein the sprayer further comprises aspaced-apart second member coupled to the first member.
 18. The vesselaccording to claim 16, wherein the first surface and the second surfaceare substantially parallel, and the second surface forms a serrated edgeabout a perimeter.
 19. A process for distributing at least onehydrocarbon fluid, comprising: A) passing the at least one hydrocarbonfluid through a conduit to a sprayer; wherein the sprayer comprises: 1)a first member forming a plurality of diverging apertures, andcomprising a first surface and a second surface.
 20. The processaccording to claim 19, wherein the at least one hydrocarbon fluidcomprises a liquid.